Process for preparing glass fiber containing polymer sheet

Abstract

A glass fiber containing polymer sheet is prepared by providing a non-woven carrier web, superposing an adhesion film over the carrier web, applying a layer of glass fibers onto the adhesion film, and laminating together the assemblage.

What is claimed is: 
     
       1. A process for preparing a glass fiber containing polymer sheet, comprising: providing a non-woven carrier web;   superposing an adhesion film immediately adjacent the non-woven carrier web;   applying a layer of uniformly distributed, randomly oriented glass fibers onto the exposed surface of the adhesion film; and   laminating together the layer of glass fibers, adhesion film, and non-woven carrier web by heating same to a temperature above the plastic set temperature of the adhesion film and compressing the layer of glass fibers, adhesion film, and carrier web, said adhesion film adhering to the non-woven carrier web, and said glass fibers being encapsulated substantially within the exposed surface region of the adhesion film.   
     
     
       2. The process for preparing a glass fiber containing polymer sheet according to claim 1, wherein the carrier web is provided continuously at a rate of from about 3 to about 15 meters per minute. 
     
     
       3. The process for preparing a glass fiber containing polymer sheet according to claim 1, wherein the non-woven carrier web is provided in a horizontal plane. 
     
     
       4. The process for preparing a glass fiber containing polymer sheet according to claim 1, wherein the glass fibers are chopped fibers applied from the discharge of a chopper. 
     
     
       5. The process for preparing a glass fiber containing polymer sheet according to claim 1, wherein the adhesion film comprises a blend of high density polyethylene and low density polyethylene. 
     
     
       6. The process for preparing a glass fiber containing polymer sheet according to claim 1, wherein the non-woven carrier web, adhesion film, and glass fibers are heated to a temperature of about 380° F. during the lamination process. 
     
     
       7. The process for preparing a glass fiber containing polymer sheet according to claim 1, wherein the lamination step is carried out in a belt press having TEFLON coated belts. 
     
     
       8. The process for preparing a glass fiber containing polymer sheet according to claim 1, wherein the glass fibers comprise bundles of filaments, each said bundle containing from about 54 to about 144 ends, said glass fibers having lengths from about one-half inch to about 3 inches.